Drill Master 92879 User manual

CUTOUT TOOL - 18 VOLCUTOUT TOOL - 18 VOL
CUTOUT TOOL - 18 VOLCUTOUT TOOL - 18 VOL
CUTOUT TOOL - 18 VOLTSTS
TSTS
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ASSEMBLY AND OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright © 2005 by Harbor Freight Tools®. All rights reserved. No portion of
this manual or any artwork contained herein may be reproduced in any shape
or form without the express written consent of Harbor Freight Tools.
For technical questions and replacement parts,please call 1-800-444-3353
92879

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SKU 92879 For technical questions, please call 1-800-444-3353
SPECIFICATIONS
Item Description
Motor 18 VDC; 20,000 RPM ±10 % (no load)
Battery 18 VDC, NI-MH, 1300 mAh; power level display
Switch Type Toggle: On / Off
Battery Charger Adapter Input: 120 VAC/60 Hz; Output: 22 VDC, 1.3A;
Charge time: one hour; Line cord: Two-prong,
polarized
Cutting Depth 1 inch (maximum)
Collet Size 0.35 inch (9 MM)
Mill Cutter Sizes 1/8 and 1/4 (dia.) inch
Overall Dimensions 15 x 14 x 4.5 inches
Accessories Milling circle cutting jig (up to 12 inch circle)
Plastic case
Weight 10.6 lbs.
SAVE THIS MANUAL
You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
GENERAL SAFETY RULES
WARNING!
READANDUNDERSTANDALLINSTRUCTIONS.Failure tofollowallinstructions
listed below may result in electric shock, fire, and/or serious injury.
SAVETHESE INSTRUCTION
1. Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust. Power tools create sparks which may ignite
the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
4. Stay alert. Watch what you are doing, and use common sense when operating a
power tool. Do not use a power tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may
result in serious personal injury.

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SKU 92879 For technical questions, please call 1-800-444-3353
5. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or
long hair can be caught in moving parts.
6. Avoid accidental starting. Carrying power tools with your finger on the Power
Switch, or plugging in battery with the Power Switch on, invites accidents.
7. Remove adjusting keys or wrenches before turning the power tool on. A wrench
or a key that is left attached to a rotating part of the power tool may result in personal
injury.
8. Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the power tool in unexpected situations.
9. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
10. Use clamps (not included) or other practical ways to secure and support the
workpiece to a stable platform. Holding the work by hand or against your body is
unstable and may lead to loss of control.
11. Do not force the tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which it is designed.
12. Do not use the power tool if the Power Switch does not turn it on or off. Any tool
that cannot be controlled with the Power Switch is dangerous and must be replaced.
13. Unplug the Battery from the unit before making any adjustments, changing
accessories, or storing the tool. Such preventive safety measures reduce the risk
of starting the tool accidentally.
14. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
15. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintained tools with a sharp cutting edge are less likely to bind and are easier to
control. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.
16. Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
17. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous when
used on another tool.
18. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
19. When servicing a tool, use only identical replacement parts. Follow
instructions in the “Inspection, Maintenance, And Cleaning” section of this
manual. Use of unauthorized parts or failure to follow maintenance instructions may
create a risk of injury or damage to the unit.

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SKU 92879 For technical questions, please call 1-800-444-3353
SPECIFIC SAFETY RULES FORTHE CUTOUTTOOL
WARNING!This tool has sharp, fast-moving parts. Misuse can cause severe injury.
Always follow the safety instructions below.
1. Hold tool by the insulated gripping handles when performing an operation
where the cutting tool may contact hidden wiring or its own cord. Contact with
“live” wire will make exposed metal parts of the tool “live” and shock the operator.
2. Under no circumstance is the CutoutTool base ever to be removed from the tool
in order to use bits that are too large to use with the base assembly attached.
Removal of the base, and using the tool “free hand” can lead to serious bodily injury.
Do not use router bits on the Cutout Tool
3. Never touch the bit, collet, or any other moving parts while the CutoutTool is in
operation.
4. Never lay the CutoutTool down until the bit has stopped rotating completely.
5. Hold the CutoutTool firmly when starting, as startup rotation creates significant
torque.
6. Never hold workpiece by hand. Secure the workpiece by clamping, or with other
holding devices.
7. Make sure the workpiece is free of nails and other obstacles. These can interfere
with the cutting process, and possibly cause damage and injury.
8. Hold the tool firmly while cutting. The action of the bit against the workpiece can
cause it to “kick out,” jumping rapidly away from the workpiece.This can be caused by
an improper type, or dull bit being used.
9. Do not handle the CutoutTool bit immediately after cutting. It may be very hot,
potentially causing burns or injury.
10. Avoid overloading the tool. If the speed drops abnormally, decrease the pressure on
the bit immediately. Do not apply excessive pressure to the tool while cutting.
11. Always use sharpened bits. If the bit stops abruptly, or the bit becomes blocked,
remove the tool from the workpiece and shut it off.
12. Never start the CutoutTool while the bit is in contact with workpiece. Allow the
tool to reach its normal operating speed before applying the bit to the workpiece.
13. Maintain labels and nameplates on the CutoutTool. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
14. Always wear ANSI approved safety impact eye goggles and heavy work gloves
when using this tool. Using personal safety devices reduce the risk for injury. Safety
impact eye goggles and heavy work gloves are available from Harbor Freight Tools.

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SKU 92879 For technical questions, please call 1-800-444-3353
15. Maintain a safe working environment. Keep the work area well lit. Make sure there
is adequate surrounding workspace. Always keep the work area free of obstructions,
grease, oil, trash, and other debris. Do not use a power tool in areas near flammable
chemicals, dusts, and vapors. Do not use this product in a damp or wet location.
16. Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Cutout Tool.
17. Never leave the CutoutTool unattended while running.Turn power off if you have
to leave the Cutout Tool.
18. Before each use, check all nuts, bolts, and screws for tightness.Vibration during
operation may cause these to loosen.
19. Only use bits rated @ or above 22,000 RPM.
WARNING! Somedustcreatedbypowersanding,sawing,grinding,drilling,andother constructionactivi-
ties,contain chemicals known(totheStateofCalifornia)to cause cancer,birthdefects or other reproductiveharm.
Someexamples of these chemicalsare:lead from lead-based paints,crystallinesilica from bricks andcementor
other masonry products, arsenic and chromium from chemically treated lumber. Your risk from these exposures
varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a
well ventilated area, and work with approved safety equipment, such as those dust masks that are specially
designed to filter out microscopic particles. (California Health & Safety Code 25249.5, et seq.)
BATTERY PRECAUTIONS
1. Read all instructions and warnings on the battery before charging the battery.
2. To avoid accidents, charge the supplied battery only. Do not use a different charger
with this battery.
3. Do not expose the battery to rain or wet conditions.
4. To avoid damage of cable and plug, never pull the cable to disconnect the charger.
5. Do not use the charger if the cable or plug are damaged.
6. Repairs should be carried out by a qualified technician.
7. Do not touch the battery poles with any conductive source.
8. Do not store the battery in a box with other metal objects.
9. Do not throw the battery in a fire or in the general trash. Contact your local hazardous
waste disposal authority for proper disposal.
10. Do not drain the battery completely before recharging.Recharge fully.
11. Always remove the battery from the tool before performing inspection, maintenance,
cleaning procedures, or storage.
12. After initial 8 hour charge, never charge Battery for more than 2 hours continuously.
Charger Adapter should not be left plugged in or charging for more than 8 hours.
(1)
WARNING! People with pacemakers should consult their physician(s) before using this product.
Electromagneticfieldsincloseproximitytoaheartpacemakercouldcauseinterferencetoorfailureofthepacemaker.

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SKU 92879 For technical questions, please call 1-800-444-3353
13. Always switch to a fresh battery (or recharge) when tool performance begins to
diminish. Severe heat is most destructive to a battery; the more heat generated, the
faster the battery loses power.A battery that gets too hot can be permanently
damaged. Never over-discharge a battery by using the tool even after tool
performance is decreasing. Never attempt to discharge a tool’s battery by continuing
to keep the tool running.When tool performance begins to diminish, stop the tool,
recharge the battery and use the fresh battery for optimal performance.
14. Recharge the battery monthly even if not used.
UNPACKING
When unpacking, check to make sure that all the parts are included. Refer to the Assembly
Drawing and Parts List at the end of this manual. If any parts are missing or broken, please
call Harbor Freight Tools at the number on the cover of this manual as soon as possible.
CHARGING BATTERY
The Battery (36) does not come charged from the factory. First time, charge for eight hours
before using.
1. Slide the Battery into the Charger Adapter (38) base. The Battery can only insert one
way. See photos at the top of page 7.
2. Plug the Charger Adapter plug into an electrical outlet.
3. Press the Set button on the Charger Adapter.
The Charging Indicator turns red, indicating charging. Charge the new Battery for
eight hours.Subsequent charges should take approximately one hour.
When charging is complete, the Charging Indicator turns green.
4. Unplug the Charger Adapter from the electrical outlet.
Cutting Bit (37)
Battery (36)
Charger Adapter (38)
Circle Guide (2, 5, and 6)
not shown
CutoutTool
Cutting Bit (40)
SpannerWrench (39)

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SKU 92879 For technical questions, please call 1-800-444-3353
5. Remove the Battery from the Charger Adapter when it is fully charged.
6. Press and hold theTEST button of the Battery.Read the Battery Display on the end of
the Battery.The (far-right) light should display green for full.
Note:The operation time of a new battery will ramp up as it is properly used (drained) and
recharged. It will take about five recharging cycles before the Battery is at maximum effi-
ciency.
Caution:If two or more batteries are to be charged,avoid damaging the Charger Adapter
by allowing it to cool down between charges.Wait for the Battery to cool down before
placing in the tool.
OPERATING INSTRUCTIONS
Caution:Before cutting or trimming,run the tool for about 10 seconds to ensure that all
moving parts are running smoothly, and there are no loose parts, rattles, or sparking
that would indicate damage. Be sure the bit is firmly and properly installed before use.
Improperly installed bits may eject suddenly at high speed from the tool.
Controls and Indicators
Battery Power Display
Battery Test Button
Charger
Adapter (38)
Battery (36)
Set Button and
Charging
Indicators
Height Adjust Knobs (9)
On / Off Switch (26)
Collet Nut (14)
Spindle Lock (22)
Button
Side Handle
Circle Cutter Jig
Pivot Screw (6)
Ball Handle (5)
Ruler (2)
Body Handle
Wheel (1)
Wheel Screw (8)

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SKU 92879 For technical questions, please call 1-800-444-3353
Installing the Cutter Bit
1. Remove the Battery (36) from the tool.
2. Insert Spanner Wrench (39) over the Collet Nut (14) and press in (and hold) the
Spindle Lock Button (22) to keep it from turning. See photo at the bottom of page 7.
Note:You may need to rotate collet nut for lock to engage.
3. Loosen the Collet Nut (14) by turning it counterclockwise, but do not remove.
4. If there is already a bit in the Collet Cone, remove it.
5. Push the shank end of the 1/8” or 1/4” size bit through the opening in the Collet Nut.
There may be some resistance, so make sure that it goes in all the way.
6. Press in on the Spindle Lock Button, then tighten the Collet Nut (clockwise) with the
Spanner Wrench. Note: The supplied bit is intended to be used for cutting drywall,
plaster and wood. Do not use on metal.
Adjusting Cutting Depth
1. Install the cutting bit as previously described.
2. Loosen (counterclockwise) both height adjustment Knobs (9) securing the Support
Cover (7) to the Support (11). Slide the Support outward so the bit is retracted.
3. Slide the Support Cover (7) in, again exposing the bit, to approximately the desired
depth.
Measure from the end of the bit to the bottom of the Wheel (1).When the desired
depth is reached, tighten height adjustment Knobs (9).
Inserting Battery
Caution: Before inserting the Battery Pack into the tool, be certain that the Switch (26)
is in the off position, the cutting bit is already installed, and all adjustments are done.
1. With the Switch (26) in the Off position, align the Battery (36) mounting guides (A)
onto the receiving guides of the tool handle bottom.
2. Push the Battery all the way in until it stops.
Height Adjustment Knobs (9)
Support Cover (7)
Support (11)
Wheel (1)
(A)

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SKU 92879 For technical questions, please call 1-800-444-3353
Best Cutting Direction
The Cutter Bit rotates clockwise.You must adjust for this while cutting.
1. For most materials it is best to move from left to right as you face the workpiece.
2. When cutting outside edges, move the tool counterclockwise.When cutting inside
edges, move the tool clockwise.
Note: It is always wise to make a test cut to assure that the tool is adjusted properly before
beginning to cut the final workpiece.
Using the Circle Guide
The Circle Guide enables cutting circles between 2-3/4 and 12 inches.
1. Assemble the Circle Guide components by placing the Pivot Screw (6), through the
Ruler (2), and secure with Nut (3). Refer to the photo below and the Assembly
Drawing. Attach Ball Handle (5) to the end of the Ruler (2) using Screw (4).
2. Hold the Wheel Screw (8) with one hand, and with the other, unscrew the Wheel (1)
counterclockwise.
3. Lift the Wheel (1) off and place the Circle Guide on the Support Cover (7) as shown
below.
4. Again, hold the Wheel Screw (8) with one hand, and with the other, screw the Wheel
(1) through the circle of the Ruler (2) clockwise until tight.
5. Install the cutter bit and set the cutting depth as described on page 8.
6. Loosen the Pivot Screw (6) and slide it to the desired circle radius as read on the
Ruler (2). Securely tighten Pivot Screw.
7. Turn the tool over and insert the Battery (36) as described on page 8.
8. Using a countersink and hammer (not supplied), tap a small hole in the stock to be
cut for the Pivot Screw (6) point to rotate in.
9. Make a test cut on scrap wood to ensure the cutting radius is correct.
Pivot Screw (6)
Nut (3)
Ball Handle (5)
Screw (4)
Wheel (1)
Wheel Screw (8)
hidden

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SKU 92879 For technical questions, please call 1-800-444-3353
Caution:To avoid cutting into the workbench top,it is recommended that the workpiece
be placed and clamped to a piece of scrap wood of the same size.
10. Place one hand on the Ball Handle (5), and the other on the Body Handle.
11. Flip the On/Off Switch (26) to the On position.When the Motor reaches full speed, drill
into the stock and begin to turn the Cutout Tool with the Ball Handle. Pivot on the
Pivot Screw (6) pointer.
12. When the cut is complete, lift the tool up and away from the workpiece. Flip the Switch
(26) to the Off position.Wait for the bit to stop turning before setting the tool down.
Cutting Holes Freehand
1. Install a cutting bit as previously described on page 8.
2. Adjust the bit cutting depth to only 1/8 inch deeper than the
material being cut (i.e., drywall).
Caution:When cutting drywall that is already mounted on the
walljoists,turnoff circuit current to, andavoidcutting,the elec-
trical cables and wires in the wall.
3. Start the cut in the center of the area, at a slight angle when
entering the material, then level out the cutter. Move the
cutter to the trim line and cut counterclockwise.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Make sure the Power Switch of the tool is in its “OFF” position and
remove the Battery (36) before performing any inspection, maintenance, or cleaning
procedures.
1. Before each use, inspect the general condition of the tool.Check for loose screws,
misalignment or binding of moving parts, cracked or broken parts, damaged electrical
wiring, and any other condition that may affect its safe operation. If abnormal noise or
vibration occurs, have the problem corrected before further use.Do not use
damaged equipment.
2. Periodically recheck all nuts, bolts, and screws for tightness.
3. Place the tool in the plastic case and store in a clean and dry location. Remove
Battery before storing.
4. Wipe the tool down with a clean cloth after every use.
5. After each use, blow out the Motor vent holes with compressed air to prevent the
buildup of dust and particles.
6. Periodically wipe the collet, adapters, and cutting bits with a light oil to prevent rust.
7. Review Battery Precautions on page 5 for maintenance information.

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SKU 92879 For technical questions, please call 1-800-444-3353
PARTS LIST
Part # Description Part # Description
1. Wheel 21. Spring
2. Ruler 22. Spindle Lock Button
3. Nut, ¼-20 23. Spring
4. Screw, ¼-20 24. Label
5. Ball Handle 25. Cover, Switch
6. Pivot Screw 26. Switch
7. Support Cover 27. Wire, 18 AWG, 5”
8. Wheel Screw 28. Wire, 18 AWG, 5”
9. Knob, Height Adjust 29. Wire, 18 AWG, 5”
10. Nut, M4 30. Piece
11. Support 31. Wire Case, ABS
12. Knob 32. Screw, 4x16
13. Screw 33. Body, Right
14. Collet Nut 34. Body, Left
15. Crimp, 1/8” 35. Label, Right
16. Bearing 36. Battery, 18V
17. Shaft 37. Cutting Bit, 1/8”
18. Motor Guide 38. Charger Adapter
19. Motor 39. Wrench, Spanner
20. Rubber Pole 40. Cutting Bit, ¼”
NOTE:Someparts are listed and shownfor illustrationpurposesonlyandarenotavailableindividuallyasreplace-
ment parts.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM INTHIS
MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR
SHEISQUALIFIEDTOMAKEANYREPAIRSTOTHEPRODUCTORTHATHEORSHEISQUALIFIED
TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOREXPRESSLYSTATESTHATALLREPAIRSANDPARTSREPLACEMENTSSHOULD
BEUNDERTAKENBYCERTIFIEDANDLICENSEDTECHNICIANSANDNOTBYTHEBUYER.THE
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTSTHERETO.

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SKU 92879 For technical questions, please call 1-800-444-3353
ASSEMBLY DRAWING